Position adjustable grapple attachment

ABSTRACT

An attachment that is configured for attachment to an arm of a piece of construction equipment. The attachment includes a pair of grapple mechanisms mounted on a main beam. Each grapple mechanism includes opposing grab arms mounted to a grab arm housing. The grab arm housings of the grapple mechanisms are each individually adjustable separate from one another relative to the main beam in one or more directions generally perpendicular to the longitudinal axis of the main beam. The attachment can fine adjust the positions of the pipe ends relative to one another until the ends align with each other, at which point the pipe ends can be welded or otherwise secured to each other while being held in position by the grapple mechanisms.

This application claims the benefit of U.S. Provisional Applicant Ser.No. 61/599,164, filed on Feb. 15, 2012 and claims the benefit of U.S.Provisional Applicant Ser. No. 61/443,737, filed on Feb. 17, 2011, andthe entire contents of both applications are incorporated herein byreference.

FIELD

This disclosure relates to an attachment that is attachable to, forexample, a trackhoe, backhoe, excavator or other piece of constructionequipment for use in, for example, positioning pipe ends to join thepipe ends together.

BACKGROUND

Positioning two large diameter pipes, such as oilfield pipes, for tie-inis extremely time consuming and can take many hours and require manyworkers and millions of dollars worth of equipment which is very costlyand slows down the production of the pipeline. In addition, the currentprocess is hazardous to the workers. Any reduction in the time and costit takes to make a tie-in connection is beneficial. In addition,improving the safety to ground workers would be beneficial.

SUMMARY

An attachment is described that is configured for attachment to an armof a piece of construction equipment, for example an excavator, atrackhoe, backhoe or the like. The attachment is configured to automatethe process of aligning pipe ends during pipe tie-in. The attachment canfine adjust the positions of the pipe ends relative to one another in x,y and z-axis directions until the ends align with each other, at whichpoint the pipe ends can be welded or otherwise secured to each other,and/or processed in other manners, other while being held in position bythe grapple mechanisms. The attachment is configured to leave room for apipe processing tool, for example a welding apparatus, to perform aprocessing operation on one or more of the pipes, such as welding thepipe ends together.

The attachment is designed to grab the ends of two separate pipes thatare going to be aligned end to end for connecting of the pipes throughwelding or other suitable connection means. The attachment is configuredto pull the two pipes together in the Z-axis direction and also alignsthem concentric to each other via independent movement in the X-axis andY-axis directions.

As used throughout the specification and claims, the word pipe or thelike, unless otherwise specified, is intended to encompass all types,shapes, and sizes of pipe that need to be laid and tied-in with othersections of pipe. The pipe can be made of any type of materialincluding, but not limited to, metal or plastic. In cross-section, thepipe can be round, square, triangular, or have other cross-sectionalshapes. In some embodiments, an end of one pipe can be connected to adevice, other than another pipe end, that may be connected to the pipe,for example a valve, through which fluid can flow. Therefore, the termpipe is intended to encompass any structure through which fluid isintended to flow.

In addition, in some embodiment, the attachment can be used to grab,manipulate and process a single section of pipe. The attachment may alsobe used to grab, manipulate and process objects other than pipe, forexample trees, logs, telephone poles, and the like.

In one embodiment, a mechanism comprises a pair of grapple mechanismsmounted on a main beam. Each grapple mechanism includes opposing grabarms mounted to a grab arm housing. The grab auus of at least one of thegrapple mechanisms are adjustable together relative to the main beam inone or more directions generally perpendicular to a longitudinal axis ofthe main beam to adjust the position of the grab arms of the at leastone grapple mechanism relative to the main beam.

In one embodiment, it is the grab arm housings of the grapple mechanismsthat are each individually adjustable separate from one another relativeto the main beam in one or more directions generally perpendicular tothe longitudinal axis of the main beam. Because the grab arms aremounted to the grab arm housings, the grab arms which grip the pipe endsmove with the grab arm housings.

Each grapple mechanism grabs a respective pipe section near the pipeends using the grab arms. Once the pipe sections are being held by thegrab arms, the grab arm housings are adjusted relative to the main beamwhich adjusts the positions of the pipe ends that are held by the grabarms. The grab arm housings are adjusted until the pipe ends align, atwhich point the pipe ends can be secured together in a conventionalmanner.

The grab arm housing can be adjustable in multiple directions generallyperpendicular to the longitudinal axis of the main beam. For example,when viewing the grab arm housing in side plan view, the grab armhousing is adjustable in left and right directions and/or up and downdirections relative to the main beam.

For each grapple mechanism, the grab arms can be actuated by anactuating cylinder connected to one of the grab arms and a timing linkinterconnecting the grab arms. Alternatively, each grab arm can beactuated by an actuating cylinder connected thereto.

A laser or other automatic alignment system can be used to facilitatealignment of the pipe ends.

The main beam of the attachment is also adjustable in position viarotation about a vertical axis and tilting about a horizontal axis. Thegrab arm housings are also adjustable in directions parallel to thelongitudinal axis of the main beam as described in US 2010/0308609 whichis incorporated herein by reference in its entirety. These adjustmentsof the main beam and the grab arm housings, together with theadjustments of the grab arm housings relative to the main in one or moredirections generally perpendicular to the longitudinal axis of the mainbeam, permit precise positioning of the grapple mechanisms to grab thepipe ends.

In another example, an attachment is provided that is attachable to anarm of construction equipment for use in positioning the ends of twopipes to join the pipe ends together. The attachment includes a mountbracket that is configured to be connectable to the arm of theconstruction equipment. A lower head assembly is rotatably mounted tothe mount bracket to permit the lower head assembly to rotate relativeto the mount bracket about a first axis. A main beam pivotally mounts tothe lower head assembly so that the main beam can pivot relative to thelower head assembly about a second axis that is substantiallyperpendicular to the first axis. A pair of grapple mechanisms aremounted on the main beam, with each grapple mechanism including opposinggrab arms mounted to a grab arm housing. Each of the grab arm housingsof the grapple mechanisms and the main beam are adjustable relative toeach other in two directions generally perpendicular to a longitudinalaxis of the main beam to adjust the relative positions of the grab armhousings and the main beam. The longitudinal axis of the main beam issubstantially perpendicular to the first axis and to the second axis,and the grab arms are actuatable between a closed position gripping thetwo pipes and an open position. In addition, each grab arm housing andthe main beam are adjustable relative to each other in a directionparallel to the longitudinal axis of the main beam. Adjustment is alsoprovided by first and second tilt actuators, with each tilt actuatorhaving a first end attached to the lower head assembly and a second endattached to the main beam.

Although the preceding paragraph mentions a pair of grapple mechanisms,it is possible that more than two grapple mechanisms can be used. Forexample, three or more grapple mechanisms could be mounted on the mainbeam. Not all of the grapple mechanisms need be adjustable in the mannerdescribed depending on the intended function of the grapple mechanism.

An example of a pipe tie-in method includes grabbing the end of a firstpipe using a first grapple mechanism mounted on a main beam, andgrabbing the end of a second pipe using a second grapple mechanismmounted on the main beam. The end of the first pipe is then aligned withthe end of the second pipe by adjusting the relative positions of thebeam and at least one of the first and second grapple mechanisms in oneor more directions generally perpendicular to a longitudinal axis of themain beam.

The described attachment improves the accuracy and the quickness thattwo pipes can be aligned for attachment through at least the followingways.

-   -   a) The arm linkage design helps to ensure that the pipes are        always centered on the arm housing helping to align the two        pipes when they are pulled together by the shift cylinders in        the z-axis direction.    -   b) The operator of the construction equipment can independently        move each arm housing relative to the main beam in the x, y or z        axis directions. The arm housings are shiftable along the        longitudinal axis of the main beam in the z-axis direction. In        addition, the arm housings are shiftable up and down relative to        the main beam in the x-axis and y-axis directions.    -   c) Ground personnel can also use a remote control device from        the ground to shift the arm housings in the various directions        during alignment of the two pipe ends. It is also possible that        the remote control device could be used to control any other        movements that may be appropriate to achieve alignment, such as        pivoting of the main beam and swiveling of the lower head        assembly, and possibly movements of the arm of the construction        equipment.    -   d) The grab arms can be opened or closed independently of each        other. In addition, a large range of pipe diameters can be        lifted by the disclosed grab arms.    -   e) A guidance system can be used to automatically align the two        pipe ends to each other. The guidance system can utilize        contact-type position sensors or non-contact type position        sensors. Contact type sensors include Linear Variable        Differential Transformers (LVDT) or Rotary Variable Differential        Transformers (RVDT). Non-contact type sensors include one or        more lasers.

In one embodiment, the guidance system can be a laser guidance systemthat employs one line laser attached to a linear actuator that hasposition feedback. Actuators, such as linear actuators, move the laseracross the two pipe ends and captures a full 3-dimensional image whichindicates the curvatures of the two pipe ends with respect to eachother. Through suitable processing of the curvature data, it can bedetermined that the pipe ends are aligned in the x, y and z directionsand determined that the pipes are parallel to each other.

DRAWINGS

FIG. 1 is an isometric perspective view of the attachment for mountingto an arm of a piece of construction equipment.

FIG. 2 is another isometric perspective view of the attachment.

FIG. 3 is a cross-sectional side plan view of the attachment.

FIG. 4 is an end plan view of one of the grapple mechanisms mounted onthe main beam.

FIG. 5 is a cross-sectional view of the grapple mechanism of FIG. 4.

FIG. 6 is an end plan view showing the grab arms actuated to grab asmall diameter pipe.

FIG. 7 is an end plan view that shows the grab arms actuated to an openposition.

FIGS. 8A-C illustrate examples of different types of misalignmentbetween pipe ends.

FIG. 9 illustrates a single laser guidance system.

FIGS. 10A-B illustrate a four laser guidance system.

FIG. 11 illustrates an LVDT guidance system.

FIGS. 12A-B illustrate a two laser guidance system.

FIG. 13 illustrates an isometric perspective view of a pipe processingtool mounted onto the attachment using a first embodiment of a mountingmechanism.

FIG. 14 illustrates an exploded view of the pipe processing tool shownin FIG. 13.

FIG. 15 illustrates a zoomed in view of the welding unit shown in FIG.14.

FIG. 16 illustrates a cross-sectional end view of the pipe processingtool shown in FIG. 13.

FIG. 17 illustrates an isometric view of the mounting mechanism formounting the pipe processing tool onto the main beam of the attachment.

FIG. 18A illustrates an isometric perspective view of the pipeprocessing tool in a closed position and mounted onto the attachmentusing a second embodiment of a mounting mechanism.

FIG. 18B illustrates an isometric perspective view of the pipeprocessing tool in an open position and mounted onto the attachmentusing the second embodiment of the mounting mechanism.

FIG. 19 illustrates a zoomed in view of the mounting mechanism shown inFIGS. 18A and 18B.

FIG. 20 illustrates an isometric perspective view of the pipe processingtool utilizing a third embodiment of a mounting mechanism.

DETAILED DESCRIPTION

With reference to FIGS. 1-3, an attachment 10 is illustrated that isconfigured to align pipe ends during pipe tie-in. The attachment 10 ismounted to an arm of a piece of construction equipment (notillustrated). The attachment 10 includes a main beam 14 that ispivotally connected to the base of a lower head assembly 16 by a pivot18. The lower head assembly 16 is rotatably connected to a mount bracket20 to permit the lower head assembly 16 to rotate or swivel 360 degreesrelative to the mount bracket about a vertical axis. The mount bracket20 detachably mounts the attachment to the arm of the constructionequipment. Tilt actuators 22, 24 extend between the lower head assembly16 and the main beam 14 to selectively tilt the main beam about thepivot 18. Further information on the construction and operation of amain beam, lower head assembly, mount bracket and the tilt actuators canbe found in US 2009/0057019 and US 2010/0308609, which are incorporatedherein by reference in their entireties.

The attachment 10 includes a pair of grapple mechanisms 26, 28 mountedon the main beam 14. With reference to FIG. 3, the grapple mechanisms26, 28 are mounted on the main beam so that each grapple mechanism isindividually adjustable relative to the main beam along the length ofthe main beam in the z-axis direction as shown by the arrows in FIG. 3.Adjustment of each grapple mechanism 26, 28 is achieved by shiftcylinders 29 which are illustrated as being disposed within the mainbeam, and which are fixed at one end to the main beam and fixed at anopposite end to the grapple mechanisms 26, 28. If desired, the shiftcylinders 29 can be located outside of the main beam. Furtherinformation on shifting grapple mechanisms on a main beam is describedin US 2010/0308609.

The spacing between the grapple mechanisms 26, 28 is sufficient to leaveroom for a pipe processing tool, for example a welding apparatus orother pipe fastening apparatus to be applied to the pipes for physicallyconnecting the pipe ends. Details of an exemplary pipe processing toolare described below with respect to FIGS. 13-20.

The grapple mechanism 26, 28 are identical in construction. Each grapplemechanism includes a grab atm housing 30 and grab arms 32 connected tothe grab arm housing.

As shown in FIGS. 1-3, each grapple mechanism 26, 28 is designed to pickup an end of a pipe 34, 36 using the grab arms 32 under the power of theconstruction equipment. The positions of the grab arm housings are thenadjusted in the x, y and/or z-axis directions as necessary to align thepipe ends 38 during pipe tie-in. The aligned ends can then be welded orotherwise secured to each other. FIGS. 1-3 illustrate multipleconcentric pipes of different diameters in order to indicate that thegrapple mechanisms can be used to grab pipes of different diameters.

The z-axis direction is considered generally parallel to the ground, orparallel to the main beam, or parallel to the pipes, or left and rightwhen viewing FIG. 3. The x-axis direction is an up and down verticaldirection generally perpendicular to the z-axis direction andperpendicular to the main beam 14 when viewing FIG. 3. The y-axisdirection is a forward and rearward direction generally perpendicular tothe z-axis direction and to the x-axis direction, and perpendicular tothe main beam 14 when viewing FIG. 3, and into and out of the page whenviewing FIG. 3.

The attachment 10 can be used in the horizontal orientation illustratedin FIG. 1 with horizontal pipe and with the main beam 14 orientedgenerally parallel to the ground. The attachment 10 can also be used ina vertical orientation (not illustrated) with vertical pipes, with themain beam 14 oriented generally perpendicular to the ground. Theattachment can also be used with pipes that are oriented at anglesbetween horizontal and vertical.

FIGS. 4 and 5 illustrate details of the grapple mechanism 26. Asindicated above, the grapple mechanism 28 is identical in constructionto the grapple mechanism 26 so it is not described separately. The grabarm housing 30 includes a rectangular beam opening 50 having a length“1” and a height “h”. The opening 50 therefore has an area (l×h) in endplan view as in FIGS. 4 and 5. The grab arm housing 30 is disposed onthe main beam 14 with the main beam extending through the beam opening.The main beam 14 is also illustrated as being generally rectangular inend plan view with a length “l_(b)” and a height “h_(b)” with an area(l_(b)×h_(b)).

The area of the main beam 14 in end plan view is less than the area ofthe opening 50 in end plan view. The area of the main beam should besufficiently less than the area of the beam opening 50 to permitrelative movements between the main beam and the beam opening in atleast one, preferably at least two, directions, namely the x-axisdirection and the y-axis direction, generally perpendicular to thelongitudinal axis (i.e. z-axis direction) of the main beam. One factorin the difference in the areas, and thus the amount of relativemovements permitted, is how much movement of the grab arm housings isexpected or desired in order to achieve alignment of the pipe ends. Thelarger the movement required, the larger the difference in area topermit such movement.

As shown in FIGS. 4 and 5, adjustment mechanisms 52 a, 52 b, 52 c, 52 dare used to adjust the grab arm housing 30 relative to the main beam 14.The adjustment mechanisms 52 a-d are fixed to the grab arm housing 30and extend into engagement with the main beam 14. In particular, theadjustment mechanism 52 a includes a flat actuating end 54 that isextendable into engagement with the right side wall (in end plan view)of the main beam. Similarly, the adjustment mechanism 52 c includes aflat actuating end 54 that is extendable into engagement with the leftside wall (in end plan view) of the main beam. The adjustment mechanism52 b includes a flat actuating end 54 that is extendable into engagementwith the bottom wall (in end plan view) of the main beam. The adjustmentmechanism 52 d includes a flat actuating end 54 that is extendable intoengagement with the top wall (in end plan view) of the main beam.

In one embodiment, the adjustment mechanisms 52 a-d are single actinghydraulic cylinders that provide approximately 1.5 inches of travel intheir respective actuation directions. However, the adjustmentmechanisms 52 a-d can be any type of extendable and retractableactuating mechanism including, for example other types of hydraulic orpneumatic cylinders or electrically operated screw drives.

The flat actuating ends 54 can be formed by replaceable wear pads, forexample a plastic material such as NYLATRON.

To move the grab arm housing 30 to the right in FIGS. 4 and 5 in they-direction, the adjustment mechanism 52 a is actuated to extend theflat actuating end 54 thereof into engagement with the right side wallof the main beam 14. At the same time, the adjustment mechanism 52 c isretracted a corresponding amount. Reaction forces force the grab armhousing 30 to move to the right relative to the main beam.

To move the grab arm housing 30 to the left in FIGS. 4 and 5, theadjustment mechanism 52 c is actuated to extend the flat actuating end54 thereof into engagement with the left side wall of the main beam 14.At the same time, the adjustment mechanism 52 a is retracted acorresponding amount. Reaction forces force the grab arm housing 30 tomove to the left relative to the main beam.

To adjust the vertical height of the grab arm housing 30, the adjustmentmechanism 52 d is actuated to extend the flat actuating end 54 thereofinto engagement with the top wall of the main beam 14. Reaction forcesforce the grab arm housing 30 to move upward relative to the main beamin the x-axis direction. Extension of the flat actuating end 54 of theadjustment mechanism 52 b into engagement with the bottom wall of themain beam 14, while the adjustment mechanism 52 d is retracted, forcesthe grab arm housing 30 to move downward relative to the main beam inthe x-axis direction. Alternatively, the adjustment mechanism 52 b couldbe eliminated and vertical adjustment both upward and downward can becontrolled by the adjustment mechanism 52 d, where retraction of theadjustment mechanism 52 d permits the grab arm housing to be verticallylowered under the force of gravity.

In the embodiment illustrated in FIGS. 4 and 5, the grab arm housing isadjustable relative to the main beam in left and right (y-axisdirections) and up and down (x-axis directions). However, the grab armhousing need not be adjustable in all of the illustrated directions.Instead, it is contemplated herein that the grab arm housing 30 could beadjustable in just a left-right direction, or in an up-down direction.

In addition, although the main beam and the beam opening 50 aredescribed as being rectangular, shapes other than rectangular arepossible such as round or triangular. In addition, the main beam and thebeam opening 50 need not have the same shape. For example, the main beamcould be round in cross-sectional view and the beam opening could berectangular.

With continued reference to FIGS. 4 and 5, the grab arms 32 are mountedto the grab arm housing. Two sets of grabs arms are provided which aredisposed on opposite sides of the grab arm housing. The first set ofgrab arms includes a single tine 60 that is suitably configured toengage the pipe. The second set of grab arms includes a pair of spacedtines 62 (see FIG. 1) also suitably configured to engage the pipe.Further information on suitable configurations of grab arms for engagingpipe is disclosed in US 2009/0057019 and US 2010/0308609. The number oftines described herein is exemplary only. Any number of tines andconfigurations of tines could be used as long as the grab arms are ableto grab the pipe and perform any other function of the grab arms.

The tine 60 is rotatably mounted to the grab arm housing by a pivot 64between the ends of the tine 60. The upper end of the tine 60 isconnected to an end of an actuating cylinder 66, for example a hydrauliccylinder, shown diagrammatically. The opposite end of the actuatingcylinder 66 is fixed to the grab arm housing 30. The tines 62 arerotatably mounted to the grab arm housing by a pivot 68. A timing link70 extends between the tine 60 and the tines 62. The tines are arrangedin a longitudinally offset manner such that the tine 60 is positionedbetween the tines 62.

The tines 60, 62 are actuatable between a closed position gripping thepipe (shown in FIGS. 1-4) and an open position (shown in FIGS. 5 and 7)to permit the grapple mechanisms to be disposed over the respectivepipes 34, 36. Extension of the actuating cylinder 66 pivots the tine 60inwardly toward the closed position. At the same time, the timing link70 connected to the tines 62 actuates the tines 62 inwardly toward theclosed position. Conversely, retraction of the actuating cylinder 66pivots the tine 60 outwardly toward the open position, with the timinglink 70 simultaneously actuating the tines 62 outwardly as well.

In an alternative embodiment, an actuating cylinder can be provided toactuate each set of tines 60, 62. Also, one of the tines could be fixedwhile only the other set of tines is actuated.

The grapple mechanisms 26, 28 can be designed for use with any size,i.e. diameter, and shape of pipe. For example, it is believed that thegrapple mechanisms 26, 28 would be suitable for round pipes betweenabout 26 inches to about 38 inches in diameter. FIG. 4 shows the grapplemechanism grabbing a 38 inch pipe while FIG. 6 shows the grapplemechanism grabbing a 26 inch pipe. However, the grapple mechanisms canbe used with pipe having other diameters. Further, as indicated above,different diameters of pipe have been shown in the drawings to make itclear that the grapple mechanisms can be used with different pipediameters.

In use, after the pipes 34, 36 have been cut and the ends 38 roughlypositioned near each other, the attachment 10 is brought by the arm ofthe construction equipment into position near the ends 38 of the twopipes 34, 36. If necessary, the main beam 14 is tilted and/or rotated bythe lower head assembly 16 and the tilt actuators 22, 24 to properlyalign the attachment with the pipe ends. Preferably, the pipe ends 38are positioned approximately midway between the two grapple mechanismsas shown in FIG. 1.

The attachment is then lowered into position so that the grapplemechanism 26 surrounds the pipe 34 and the grapple mechanism 28surrounds the pipe 36 as shown in FIG. 5. The grab arms are thenactuated to bring the tines 60, 62 to the closed position shown in FIGS.1-4 so as to grab the pipes 34, 36.

If necessary, the positions of one or both of the grapple mechanisms 26,28 along the main beam are adjusted in the z-axis direction to bring thepipe ends closer to each other. The operator then actuates the variousadjustment mechanisms 52 a-d as needed to fine adjust the positions ofthe grab arm housings. Because the tines 60, 62 are gripping the pipes,and the tines are fixed to the grab arm housings, the pipe ends movewith the grab arm housings. Thus, the adjustment mechanisms 52 a-d canbe used to fine adjust the positions of the pipe ends to achievealignment.

Alignment can be achieved visually by the operator visually inspectingthe relative positions between the pipes, and then adjusting the pipepositions as necessary until alignment is achieved. Alternatively, asdiscussed further below, an automatic guidance or alignment system canbe employed. In addition, alignment can be achieved using a combinationof visual and automatic guidance, with the operator roughly aligning thepipe ends visually and once rough alignment is achieved, using theautomatic guidance system to finish the alignment process.

FIGS. 8A-C illustrate various types of misalignment between the pipeends that can occur. In FIG. 8A, there is an angular and offsetmisalignment between the ends along one or two axes. In FIG. 8B, thepipe ends are parallel but offset in one or two axes. In FIG. 8C, thereis angular misalignment. The described attachment can be used to correctthese and other misalignments between the pipe ends.

In an embodiment, an automatic guidance or alignment system can beemployed to automatically align the two pipe ends to each other. Theguidance system can be any type of system that would be suitable toalign pipe ends. For example, the guidance system can utilizecontact-type position sensors or non-contact type position sensors.Examples of contact type sensors include, but are not necessarilylimited to, Linear Variable Differential Transformers (LVDT) or RotaryVariable Differential Transformers (RVDT). Non-contact type sensorsinclude, but are not necessarily limited to, one or more lasers.

FIG. 9 illustrates a guidance system that uses a single laser 80. Thelaser 80 is a line laser that can be fixed to or mounted on a suitablelocation of the lower head assembly 16, for example on the flange 82that receives the pivot 18 (see FIG. 1). The laser 80 is mounted on alinear actuator 84 that is moveable in the z-axis direction, and alinear position feedback 86 provides information on the linear locationof the laser. The linear actuator 84 moves the laser 80 across the twopipes 36, 38. The line laser 80 shoots a line that captures a portion ofthe 3-dimensional curvature of the pipes. In use, the line laser 80captures the curvature profile of the pipe 36 as the laser is moved inthe z-axis direction, and the data there is translated into pipeposition. The laser then moves across to the pipe 34 and captures thecurvature profile of the pipe 34 as the laser is moved in the z-axisdirection, and the data there is translated into pipe position. The pipepositions are then compared and the pipes are adjusted using the grapplemechanisms 26, 28. This process can be repeated as necessary until thecaptured pipe positions match, thereby indicating alignment of thepipes.

FIGS. 10A-B illustrate a guidance system that uses four lasers 90 a-d.The lasers 90 a, b and 90 c, d are mounted at the 12 o'clock and 3o'clock positions relative to the pipe ends 18. The lasers 90 a, 90 ccan be fixed to or mounted on a suitable location of the lower headassembly 16, for example on the flange 82 that receives the pivot 18(see FIG. 1). The lasers 90 b, 90 d can be mounted to a suitablemounting bracket that is fixed to the flange 82 or other location on tothe lower head assembly 16. The lasers 90 a, 90 b measure the distancesto the pipe 36 while the lasers 90 c, 90 d measure the distances thepipe 34. The distances are then compared. When the difference is zero,the pipes are aligned on the respective axis. Any differences in thedistances are corrected by adjusting the pipe ends using the grapplemechanisms 26, 28.

FIG. 11 illustrates a guidance system that employs four LVDT's 100 a-din place of the lasers 90 a-d. The LVDT's would provide a contact typesensing approach instead of the non-contact sensing of lasers.

FIGS. 12A-B illustrate a guidance system that employs two lasers 110 a,110 b. The lasers 110 a, 110 b are fixed to or mounted on a suitablelocation of the lower head assembly 16 at 12 o'clock (110 a) and 3o'clock (110 b) positions so that they are stationary relative to thepipes and grapple mechanisms. The lasers 110 a, 110 b bridge the twopipes to measure the distances to the pipes 34, 36 as in FIGS. 10A-B,with the distances then being compared to achieve alignment.

Other types of guidance systems could be employed to automatically alignthe pipe ends.

Once the pipe ends are aligned, they can be joined together in anysuitable manner. One example is welding the pipe ends to each other.Welding can be performed manually by someone on the ground usingconvention welding equipment. Welding could also be performed using apipe processing tool that is mounted on the attachment 10. Withreference to FIGS. 13-20, an example of a pipe processing tool isillustrated.

In addition to or separately from welding, other pipe processingoperations can be performed using the pipe processing tool mounted onthe attachment. Examples of other pipe processing operations includescoating one or more of the pipe ends, painting the pipes, cutting one ormore of the pipes, applying a seal to seal the pipe ends, beveling oneor more of the pipe ends, or sand blasting one or more of the pipe ends.Other processing operations are possible. Depending upon the processingoperation, the processing operation can be performed before or after thepipe ends are aligned with each other.

FIGS. 13-19 illustrate a pipe processing tool 200 mounted on theattachment 10 using two different mounting mechanisms 300, 350, whileFIG. 20 illustrates the pipe processing tool that includes a mountingmechanism 375 that is used to free hang the tool separate from theattachment 10 on any suitable equipment such as a crane, a boom arm, acherry picker, and the like. In the illustrated embodiment, the pipeprocessing tool 200 is configured for welding and therefore it includesa welding unit 210 movably secured onto a generally circular track 220having a plurality of gear teeth 224.

The welding unit 210 includes a laser 211, a proximity sensor 212, awelding lead 213 and a motorized gear 214 (see FIGS. 15 and 16) fixed toa welding base 215. The laser 211 is used as a guidance tool for thewelding lead 213. The proximity sensor 212 is used to measure theposition of the welding lead 213 to the pipe surface being welded. Inthis embodiment, the proximity sensor 212 is a spring loaded proximitysensor that includes a roller 216 that rolls along the outer surface ofthe pipe to be welded. In other embodiments, other types of contact typeposition sensors or non-contact type position sensors can be used inplace of the proximity sensor 212. The motorized gear 214 is driven by amotor 217 and is in driving engagement with the circular track 220. Themotorized gear 214 in conjunction with the gear teeth 224 allows thewelding unit 210 to move along the entire track 220 around thecircumference of the pipe.

The track 220 is configured to fit around the outer surface of the twopipes 34, 36 held by the attachment 10 that are to be welded together.The welding unit 210 and the track 220 are surrounded by a generallycircular cage 225. The cage 225 includes a plurality of contact surfaces230 along an inner circumference of the cage 225. The plurality ofcontact surfaces 230 provide multiple points of contact along the outersurfaces of the pipes 34, 36 to be welded together. The contact surfaces230 provide additional support for holding the pipes 34, 36 while thewelding unit 210 welds the pipe 34 to the pipe 36. The cage 225 is sizedso as to allow the welding unit 210 to slide along the track 220 withoutinterference from the cage 225.

The pipe processing tool 200 also includes a mounting unit 240 formounting the pipe processing tool 200 to the attachment 10. The mountingunit 240 includes an attachment support 242 and a receiver housing 244.The receiver housing 244 receives the attachment support 242 and issecured to a mounting mechanism, such as the mounting mechanism 300shown in FIG. 13 and the mounting mechanism 350 shown in FIGS. 18A, 18Band 19.

As shown in FIG. 14, the track 220 is made up of two generally halfcircular tracks 222 a, 222 b and the cage 225 is made up of twogenerally half circular shaped cages 227 a, 227 b. The cage 227 a issecured to the cage 227 b at a top end by the attachment support 242.

The pipe processing tool 200 also includes a pair of linear actuators246 a, 246 b. A first end of the linear actuators 246 a, 246 b are fixedto the attachment support 242. A second end of the linear actuators 246a, 246 b are fixed to a portion of the cages 227 a, 227 b, respectively.In one embodiment, the linear actuators 246 a, 246 b are double actinghydraulic cylinders. However, the linear actuators 246 a, 246 b can beany type of extendable and retractable actuating mechanism including,for example other types of hydraulic or pneumatic cylinders orelectrically operated screw drives.

A bottom end of the cage 227 a includes a first latch housing 248 and abottom end of the cage 227 b includes a second latch housing 249. Alatching unit 250 is fixed to the first latch housing 248 and isconfigured to latch the first latch housing 248 to the second latchhousing 249, thereby connecting the bottom end of the cage 227 a to thebottom end of the cage 227 b. The latching unit 250 causes the pipeprocessing tool 200 to provide a clamping force to clamp and to properlyalign the ends of the pipes 34, 36 so as to be concentric for pipeprocessing.

As shown in FIGS. 14 and 16, the latching unit 250 includes a latchlinear actuator 251 that is pivotally fixed at one end to a latch mount256 in the first latch housing 248. A generally hook shaped latch head252 is pivotally fixed to a second end of the latch linear actuator 251.The latching unit 250 also includes a latch flap 254 that is pivotallyfixed to an end of the latch head 252 where the latch head 252 ispivotally fixed to the latch linear actuator 251.

When clamping the first latch housing 248 to the second latch housing249, the latch linear actuator 251 extends the latch head 252 so as toride over the top of a latch catch 258 on the second latch housing. Thelatch linear actuator 251 then retracts, thereby pulling the latch head252 into the latch catch 258 and clamping the first latch housing 248 tothe second latch housing 249. This causes the pipe processing tool 200to clamp the pipes 34, 36 concentrically to each other.

When unclamping the first latch housing 248 from the second latchhousing 249, the latch linear actuator 251 extends the latch head 252,causing the latch flap 254 to extend beyond and ride over the top of thelatch catch 258. The latch linear actuator 251 is then retracted so thatthe latch flap 254 pivots, causing the latch head 252 to ride over thelatch catch 258 instead of pulling the latch head 252 into the latchcatch 258.

FIGS. 13 and 17 illustrate the pipe processing tool 200 mounted on themain beam 14 via a mounting mechanism 300 according to one embodiment.The mounting mechanism 300 includes a pair of pins 305 mounted onto themain beam 14, a pair of scissor hinge mechanisms 310 and a longitudinaltrack 315. Each of the scissor hinge mechanisms 310 are mounted to arespective one of the pins 305. The longitudinal track 315 includes aplurality of gear teeth 317 and is connected at opposing ends to each ofthe scissor hinge mechanisms 310 and extends in a direction generallyparallel to the main beam 14. The receiver housing 244 of the pipeprocessing tool 200 is movably attached to the longitudinal track 315.

In this embodiment, a motor 320 and a gear 322 are fixed to the receiverhousing 244 of the pipe processing tool 200. The motor 320 and the gear322 in conjunction with the gear teeth 317 allow the receiver housing244, and therefore the pipe processing tool 200, to move along the track315. Thus, the position of the pipe processing tool 200 can be altered,with respect to the attachment 10, in a direction generally parallel tothe main beam 14 along the z-axis.

Both of the scissor hinge mechanisms 310 are identical in construction.Each scissor hinge mechanism 310 includes a top hinge 312 a that pivotsabout a top pivot 311 a and a bottom hinge 312 b that pivots about abottom pivot 311 b. Opposing ends of the top hinge 312 a are connectedto the respective opposing ends of the bottom hinge 312 b. In thisembodiment, a rod 313 and a motor 314 are connected to the opposing endsof the top hinge 312 a and the bottom hinge 312 b and allow the tophinge 312 a and the bottom hinge 312 b to pivot about the top pivot 311a and the bottom pivot 311 b. The motor 314 controls the angle of thetop hinge 312 a about the top pivot 311 a and the angle of the bottomhinge 312 b about the bottom pivot 311 b, thereby controlling theposition of the track 315 with respect to the attachment 10 in agenerally vertical direction along the x-axis. Thus, the scissor hingemechanisms 310 are capable of altering the position of the pipeprocessing tool 200, with respect to the attachment 10, in a generallyvertical direction along the x-axis. In other embodiments, the rod 313and the motor 314 can be positioned at other positions on the scissorhinge mechanism 310. For example, in another embodiment, the rod 313 canbe positioned at the top pivot 311 a and the motor 314 can be positionedat the bottom pivot 311 b. In other embodiments, a motor or rod can beconnected at the opposing ends of the top hinge 312 a and the bottomhinge 312 b as well as the top pivot 311 a and the bottom pivot 311 b.

In some embodiments, the mounting mechanism 300 is capable of alsoaltering the position of the pipe processing tool 200 with respect tothe attachment 10 in a direction generally perpendicular to the x-axisdirection and the z-axis direction.

Electrical power for the welding unit 210 and the motors 314, 320 andhydraulic power for the actuators 246 a, 246 b, 251 are provided by wayof suitable connections to sources on the head assembly 16 or othersuitable sources external to the tool 200.

The configuration of the tool 200 allows other pipe processing unitsthat perform other processing operations to be mounted to the tool 200.For example, the welding unit 210 can be replaced with a spray coatingmechanism that can ride on the track 220 for applying a coating aroundthe ends of the pipes at or near the joint. Of course, as indicatedabove, other pipe processing operations could be performed usingsuitably configured units.

FIGS. 18A, 18B and 19 illustrate the pipe processing tool 200 mounted onone of the grab arm housings 30 via a mounting mechanism 350, accordingto another embodiment. The mounting mechanism 350 includes a pair oflinear actuating slide mounts 355 mounted onto a side surface of thegrab arm housing 30, a receiver base 360 and a linear actuator 365. Thereceiver base 360 is attached to the receiver housing 244 of the pipeprocessing tool 200. The linear actuator 365 is pivotally attached atone end to the receiver base 360 and is pivotally attached at the otherend to the attachment support 242 of the pipe processing tool 200.

In one embodiment, the linear actuator 365 is a double acting hydrauliccylinder. However, the linear actuator 365 can be any type of extendableand retractable actuating mechanism including, for example other typesof hydraulic or pneumatic cylinders or electrically operated screwdrives.

The receiver base 360 is movably mounted to the pair of linear actuatingslide mounts 355, such that the receiver base 360 is capable of moving,with respect to the attachment 10, in a generally vertical directionalong the x-axis. Thus, the mounting mechanism 350 is capable ofaltering the position of the pipe processing tool 200 with respect tothe attachment 10 in a generally vertical direction along the x-axis. Insome embodiments, the receiver base 360 position is controlled by thelinear slide mounts 355.

In this embodiment, the attachment support 242 is movably secured to thereceiver housing 244, such that the attachment support 242 can slideinto and out of the receiver housing 244 in a direction generallyparallel to the main beam 14 along the z-axis. The linear actuator 365allows a user to adjust the position of the attachment support 242within the receiver housing 244 in a direction generally parallel to themain beam 14 along the z-axis. By adjusting the linear actuator 365, theattachment support 242 is capable of moving with respect to theattachment 10 in a direction generally parallel to the main beam 14along the z-axis. Thus, the mounting mechanism 350 is capable ofaltering the position of the pipe processing tool 200 with respect tothe attachment 10 in a direction generally parallel to the main beam 14along the z-axis.

In some embodiments, the mounting mechanism 350 is capable of alsoaltering the position of the pipe processing tool 200 with respect tothe attachment 10 in a direction generally perpendicular to the x-axisdirection and the z-axis direction.

FIG. 20 illustrates the pipe processing tool 200 secured to a mountingmechanism 370 according to yet another embodiment. The mountingmechanism 370 includes a bracket 375 that secures the attachment support242 of the pipe processing tool 200. The mounting mechanism 370 alsoincludes a clevis 380 pivotally mounted to the top of the bracket 375.The clevis 380 allows the mounting mechanism 370, and thereby the pipetool 200, to freely suspend from an attachment, such as the attachment10 shown in FIG. 1. Alternatively, the pipe processing tool 200 can befreely hung using a chain or cable attached to a general liftingmachine, for example a crane, boom arm, loader, cherry picker, etc. Inone such embodiment, a crane cable can be attached to the clevis 380 andthrough the use of a remote power source (not shown) operate the pipeprocessing tool 200 to perform all of the before described activities.Thus, in the embodiment of FIG. 20, the processing tool 200 can be usedseparately from, i.e. not attached to, the attachment 10.

The illustrated pipe processing tool and associated mounting mechanismsare exemplary only. Any pipe processing tool and associated mountingmechanism that can be incorporated onto the attachment 10 to perform apipe processing operation on one or more of the pipes can be used.

The embodiment illustrated in FIG. 1 shows the use of one attachment,having two grapple mechanisms, mounted on the main beam 14. It iscontemplated that separate attachments could be utilized, each havingone or two grapple mechanisms, with each attachment being connected toarms of separate construction equipment, with one attachment grabbingand adjusting one pipe end and the other attachment grabbing andadjusting the other pipe end. Also, two grapple mechanisms could be usedto grab each pipe.

The examples disclosed in this application are to be considered in allrespects as illustrative and not limitative. The scope of the inventionis indicated by the appended claims rather than by the foregoingdescription; and all changes which come within the meaning and range ofequivalency of the claims are intended to be embraced therein.

1-19. (canceled)
 20. A method of aligning an end of a first pipe with anend of a second pipe along x, y, z axes, the method comprising: a)attaching a grapple attachment to an arm of construction equipment, thegrapple attachment includes an alignment system that has a firstplurality of non-contact type sensors that are spaced circumferentiallyfrom one another and that face in the same direction toward an exteriorsurface of the first pipe; b) simultaneously grabbing the end of thefirst pipe and the end of the second pipe using the grapple attachment;c) using the first plurality of non-contact type sensors to determinealignment between the end of the first pipe and the end of the secondpipe; d) based on the determined alignment, using the grapple attachmentto adjust the position of the end of the first pipe and/or the end ofthe second pipe along one or more of the x, y and z axes; e) repeatingsteps c) and d) if necessary until the end of the first pipe is alignedwith the end of the second pipe along the x, y and z axes.
 21. Themethod of claim 20, wherein the alignment system has a second pluralityof non-contact type sensors that are spaced circumferentially from oneanother and that face in the same direction toward an exterior surfaceof the second pipe; step c) includes using the first plurality ofnon-contact type sensors and using the second plurality of non-contacttype sensors to determine alignment between the end of the first pipeand the end of the second pipe; and step d) includes based on thedetermined alignment in step c), using the grapple attachment to adjustthe position of the end of the first pipe and/or the end of the secondpipe along one or more of the x, y and z axes.
 22. The method of claim20, wherein the first plurality of non-contact type sensors include afirst sensor and a second sensor that is spaced 90 degrees from thefirst sensor.
 23. A grapple attachment that can simultaneously grab afirst pipe and a second pipe, comprising: a mount bracket configured todetachably connect the grapple attachment to an arm of constructionequipment; a lower head assembly rotatably connected to the mountbracket for rotation about an x-axis; a main beam pivotally connected tothe lower head assembly for pivoting movement of the main beam about ay-axis; a first grapple mechanism and a second grapple mechanism mountedon the main beam; the first grapple mechanism is configured to grab thefirst pipe, and the second grapple mechanism is configured to grab thesecond pipe; and the first grapple mechanism and the second grapplemechanism are adjustable relative to the main beam along a z-axisdirection, along an axis parallel to the y-axis, and along an axisparallel to the x-axis; an alignment system that has a first pluralityof non-contact type sensors that are spaced circumferentially from oneanother and that face in the same direction toward an exterior surfaceof the first pipe when the first pipe is grabbed by the first grapplemechanism.
 24. The grapple attachment of claim 23, wherein the alignmentsystem includes a second plurality of non-contact type sensors that arespaced circumferentially from one another and that face in the samedirection toward an exterior surface of the second pipe when the secondpipe is grabbed by the second grapple mechanism.